Models
GP8045 / GP8048
Triplex Ceramic
Plunger Pump
Models Manual
Contents:
Installation Instructions: page 2
Pump Specifications (GP8045): page 3
Exploded View page 4
Parts List: page 5
Pump Specifications (GP8048): page 6
Repair Kits/Tool List:/Torque Specifications page 7
Troubleshooting Chart: page 7
Repair Instructions: pages 8-10
Dimensions: page 11
Warranty Information back page
INSTALLATION INSTRUCTIONS
Installation of the Giant Industries, Inc., pump is not a
complicated procedure, but there are some basic steps
common to all pumps. The following information is to be
considered as a general outline for installation. If you
have unique requirements, please contact Giant Industries, Inc. or your local distributor for assistance.
1. The pump should be installed flat on a base to a
maximum of a 15 degree angle of inclination to ensure
optimum lubrication.
2. The inlet to the pump should be sized for the flow rate
of the pump with no unnecessary restrictions that can
cause cavitation. Teflon tape should be used to seal all
joints. If these pumps are to be operated at temperatures
in excess of 86o F, it is important to insure a positive head
to the pump to prevent cavitation.
3. The discharge plumbing from the pump should be
properly sized to the flow rate to prevent line pressure
loss to the work area. It is essential to provide a safety
bypass valve between the pump and the work area to
protect the pump from pressure spikes in the event of a
blockage or the use of a shut-off gun.
5. Crankshaft rotation on Giant Industries, Inc.
pumps should be made in the direction designated by
the arrows on the pump crankcase. Reverse rotation
may be safely achieved by following a few guidelines
available upon request from Giant Industries, Inc.
Required horsepower for system operation can be
obtained from the charts on pages 3 and 6.
6. Before beginning operation of your pumping
system, remember: Check that the crankcase and seal
areas have been properly lubricated per recommended schedules. Do not run the pump dry for
extended periods of time. Cavitation will result in
severe damage. Always remember to check that all
plumbing valves are open and that pumped media
can flow freely to the inlet of the pump.
The service life of the seals is
maximized if a minimal amount of leakage is
present. A few drops of water can drip from
each plunger every minute. Leakage has to be
examined every day; the plunger seals must be
changed should leakage become excessive
(=constant dripping).
4. Use of a dampener is necessary to minimize pulsation
at drive elements, plumbing, connections, and other
system areas. The use of a dampener with Giant Industries, Inc. pumps is optional, although recommended by
Giant Industries, Inc. to further reduce system pulsation.
Dampeners can also reduce the severity of pressure
spikes that occur in systems using a shut-off gun. A
dampener must be positioned downstream from the
unloader.
IMPORTANT OPERATING CONDITIONS
Failure to comply with any of these conditions invalidates the warranty
1. Prior to initial operation, add oil to crankcase so that
oil level is between the two lines on the oil dipstick. DO
NOT OVERFILL.
Use Industrial synthetic gear lube oil (ISO VG 220),
such as Mobil Gear 630, Shell Oamala oil 220 or
Texaco Meropa 220.
Crankcase oil should be changed after the first 50 hours
of operation, then at regular intervals of 500 hours or
less depending on operating conditions.
2. Pump operation must not exceed rated pressure,
volume, or RPM. A pressure relief device must be
installed in the discharge of the system.
Finally, remember that high pressure operation in a
pump system has many advantages. But, if it is
used carelessly and without regard to its potential
hazard, it can cause serious injury.
4. Run the pump dry approximately 10 seconds to
drain the water before exposure to freezing temperatures.
5. The pump and cooling system must
be emptied if there is a danger of frost. Note that
travel wind, for example, can cause water in pumps
fitted on open vehicles to freeze even if the outside
temperature is above freezing point.
To empty the cooling circuit, remove the L-joints
(K11) on the pump head (50). Blow out the circuit
liquid at the joint connection (K11/K7) using
compressed air.
The torque tension on the valve casing nuts (49A)
should be checked after approximately 200 operating
hours. Please see page 8 for torque values.
3. Acids, alkalines, or abrasive fluids cannot be pumped
unless approval in writing is obtained before operation
from Giant Industries, Inc. Pump fluid should be filtered
to 300 micron.
2
Specifications
Model GP8045
U.S. (Metric)
Volume .............................................................Up to 48.9 GPM ...... (185 LPM)
Discharge Pressure .........................................Up to 4350 PSI........ (300 bar)
Speed ...............................................................Up to 580 RPM ....... 580 RPM
Inlet Pressure...................................................Up to 29 PSI............ (2.0 bar)
Plunger Diameter............................................. 1.77” ........................ 45mm
Plunger Stroke .................................................2.83” ........................ 72mm
Crankshaft Diameter........................................2.76”........................ 70mm
Key Width........................................................0.55” ........................ 14mm
Crankshaft Mounting......................................................................... Either side
Shaft Rotation.................................................................................... Top of pulley towards manifold
T emperature of Pumped Fluids........................Up to 86
Inlet Ports .......................................................................................... (2) 3” BSP
Discharge Ports ................................................................................. (2) 1-1/4” BSP
Weight ..............................................................705 lbs. .................... (320kg)
Crankcase Oil Capacity ...................................3.3 Gal. .................... (12.5 liters)
Fluid End Material............................................Nickle plated Spheroidical Cast Iron
o
F .............. (30 oC)
Consult the factory for special requirements that must be met if the pump is to
operate beyond one or more of the limits specified above.
HORSEPOWER RATINGS:
GP8045 HORSEPOWER
REQUIREMENTS
RPM GP M 1000 PS I 20 00 PS I 3000 PS I 4350 P S I
300 25.3 17.4 34.9 52.3 75.9
400 33.7 23.2 46.5 69.7 101.1
500 42.2 29.1 58.2 87.3 126.6
580 48.9 33.7 67.5 101.2 146.7
an electric motor as the power
source. To compute specific pump
SPECIAL NOTE:
The theoretical gallons per revolution (gal/rev) is 0.0843.
T o find specific outputs at various RPM, use the formula:
The rating shown are the power
requirements for the pump. Gas
engine power outputs must be
approximately twice the pump
power requirements shown above.
We recommend a 1.15 service
factor be specified when selecting
horse power requirements, use the
following formula:
GPM X PSI
1450
= HP
GPM = 0.0843 x RPM
3
EXPLODED VIEW -- GP8045 / GP8048
Item Part Description Qty
1 05380 Crankcase 1
2 06893 Oil Filler Plug Assy 1
5 22929 Copper Washer 2
6 06273 Oil Drain Plug 1
7 05381 Plug, Oil Dip Stick 1
8 05035 Oil Dip Stick Ass’y 1
9 01009 O-Ring 1
12 07109 Plug G-1/2 2
13 06272 Copper Ring 2
14 05036 Bearing Cover Closed 1
14A 05298 Bearing Cover Open 1
15 05112 Radial Shaft Seal 1
16 05037 O-ring 2
17 05038 Inner Hexagon Screw 16
18 05039 Spring Ring 16
21 05044 Tapered Roller Bearing 2
21A 05042 Fitting Disc 1-5
21B 05043 Fitting Disc 1-5
22 05299 Crankshaft 1
23 05300 Fitting Key 1
24 05047 Conn-rod Assy 3
25 05048 Crosshead c/w Plunger 3
28 05049 Crosshead Pin 3
29 05051 Hexagon Screw 4
29A 05382 Bracket 1 - Cooling Hose 2
29B 05383 Bracket 2 - Cooling Hose 2
30 05052 Cover Plate 1
30A 07225-0100 Screw 316 S.S 5
30B 13136 Grommet 5
30C 08280 Washer 9
30D 05050 Splash Cover 1
31 07623 Eye Bolt 3
32 05058 Radial Shaft Seal 3
33A 05056 O-Ring 3
33B 05054 Clip Ring 3
33C 05059 Fitting Disc 3
34 05060 Oil Shield 3
36B 05384 Plunger Pipe (GP8048) 3
36B 05385 Plunger Pipe (GP8045) 3
36C 05062 Tension Screw 3
36D 07665 Copper Washer 3
36E 06900 Centering Sleeve 3
38 05386 Seal Case 3
38A 05387 O-Ring 6
39 05388 Seal Case (GP8048) 3
39 05389 Seal Case (GP8045) 3
39A 05066 O-Ring 3
40 05390 Seal Ring (GP8048) 3
40 13290 Seal Ring (GP8045) 3
41 05391 Pressure Ring (GP8048) 3
41 05392 Pressure Ring (GP8045) 3
42 05393 Sleeve (GP8048) 9
42 05394 Sleeve (GP8045) 9
43 05395 Support Ring (GP8048) 3
Item Part Description Qty
43 05396 Support Ring (GP8045) 3
45 05279 Pressure Ring (GP8048) 3
45 07636 Pressure Ring (GP8045) 3
49 05072 Stud Bolt 8
49A 05073 Hexagon Nut 8
50 05397 Valve Casing 1
50A 13162 Centering Stud 2
50B 05398 Discharge Casing 1
51 05399 Suction Valve Ass’y 3
51A 08281 Spring Tension Cap 3
51B 05400 Suction V alve Seat 3
51C 05314 V alve Plate 3
51D 05401 O-Ring 3
51E 07732-0100 Valve Spring 3
51F 08282 Valve Spring Guide 3
52 05406 Discharge V alve Ass’y . 3
52A 08281 Spring Tension Cap 3
52B 05407 Discharge V alve Seat 3
52C 05314 V alve Plate 3
52D 05408 O-Ring 6
52E 07732-0100 Valve Spring 3
52F 08282 Valve Spring Guide 3
56 05409 Discharge V alve Adapter 3
56A 05408 O-Ring 3
57 07173 Tension Spring 6
58 05087 Hexagon Socket Screw 12
59 07109 Plug G-1/2 2
59A 06272 Copper Gasket 2
60 06909 Plug G 1-1/4 1
61 05088 Plug G-3 1
62 05302 Plug G-1/4 6
62A 06934 Copper Gasket 6
66 05303 Disc for Crankshaft 1
67 13433 Hexagon Screw 1
78 05052 Oil Cooler 1
79 07662 Tool for Valve 1
K1 05026 Cooling Vane Plate 1
K2 05027 Seal for Gear Cover 2
K3 05028 Gear Cover 1
K4 05029 Hexagon Head Countersunk
Screw 8
K5 07381 Hexagon Socket Screw 8
K6 08041 Washer 8
K7 05030 Connection for Oil Cooler 1
K8 06272 Copper Seal 6
K9 07109 Plug G1/2 2
K10 05031 Connecting Branch 3
K11 05032 U-Joint Connector w/Nut 3
K12 05033 Tube for Cooler 2
K13 05402 Hose Clamp 4
K14 05403 Hose Guard 2
K15 05404 Hose Coupling Nut 1
K16 05405 Flat Gasket for Oil Cooler 4
Specifications
Model GP8048
U.S. (Metric)
Volume .............................................................Up to 56.8 GPM ...... (215 LPM)
Discharge Pressure .........................................Up to 3770 PSI........ (260 bar)
Speed ...............................................................Up to 580 RPM ....... 580 RPM
Inlet Pressure...................................................Up to 29 PSI............ (2.0 bar)
Plunger Diameter.............................................1.89” ........................ 48mm
Plunger Stroke .................................................2.83” ........................ 72mm
Crankshaft Diameter........................................2.76”........................ 70mm
Key Width........................................................0.55” ........................ 14mm
Crankshaft Mounting......................................................................... Either side
Shaft Rotation.................................................................................... Top of pulley towards manifold
T emperature of Pumped Fluids........................Up to 86
Inlet Ports .......................................................................................... (2) 3” BSP
Discharge Ports ................................................................................. (2) 1-1/4” BSP
Weight ..............................................................705 lbs./ ................... (320kg)
Crankcase Oil Capacity ...................................3.3 Gal. .................... (12.5 liters)
Fluid End Material............................................Nickle plated Spheroidical Cast Iron
o
F .............. (30 oC)
Consult the factory for special requirements that must be met if the pump is to
operate beyond one or more of the limits specified above.
GP8048 HORSEPOW ER
REQUIREMENTS
RPM GP M 1000 PS I 2000 P S I 3000 P S I 3770 P S I
300 29.4 20.3 40.6 60.8 76.4
400 39.2 27.0 54.1 81.1 101.9
500 49.0 33.8 67.6 101.4 127.4
580 56.8 39.2 78.3 117.5 147.7
SPECIAL NOTE:
The theoretical gallons per revolution (gal/rev) is 0.0979.
T o find specific outputs at various RPM, use the formula:
HORSEPOWER RATINGS:
The rating shown are the power
requirements for the pump. Gas
engine power outputs must be
approximately twice the pump
power requirements shown above.
We recommend a 1.15 service
factor be specified when selecting
an electric motor as the power
source. To compute specific pump
horsepower requirements, use the
following formula:
GPM X PSI
1450
= HP
GPM = 0.0979 x RPM
6
GP8045/GP8048 PUMP REPAIR KITS
p
g
p
p
p
r
g
p
Plunger Packing Kits
GP8045 - #09626
Item Part # Description Qty.
38A 05387 O-Ring 6
39A 05066 O-Ring 3
40 13290 Seal Ring 3
42 05394 V-Sleeve 9
Valve Assembly Kit - GP8045 & GP8048
Inlet Valve Kit - #09628
Item Part # Description Qty.
51B 05400 Inlet Valve Seat 3
51C 05314 Valve Plate 3
51D 05401 O-Ring 3
51E 07732-0100 Valve Spring 3
51F 08282 Valve Spring Guide 3
GP8048 - #09627
56A 05410 O-Ring 3
Item Part # Description Qty.
38A 05387 O-Ring 6
39A 05066 O-Ring 3
40 05390 Seal Ring 3
42 05393 V-Sleeve 9
Discharge Valve Kit - #09629
Item Part # Description Qty.
52B 05407 Discharge Valve Seat 3
52C 05314 Valve Plate 3
52D 05408 O-Ring 3
Oil Seal Kit - #09584
Item Part # Description Qty.
32 05058 Radial Shaft Seal 3
52E 07732-0100 Valve Spring 3
52F 08282 Valve Spring Guide 3
56A 05410 O-Ring 3
33A 05056 O-Ring 3
GP8045/GP8048 TOOL LIST AND TORQUE SPECIFICATIONS
ITEM PAR T # D E SCRIPTION TORQUE Ft-lbs (NM) TOOL NEEDED
17 05038 Hexagon Socket Screw 64 (87) 10mm allen wrench
24 05047 Connecting Rod Hexago n Socket Screw 37 (50) 8mm allen wrench
33B 05 054 Clip Ring n/a Ind us t r ial Snap ring pliers
36C 05062 Tension Screw 30 (40) 16mm socket
49A 05073 Hexagon Nut (manifold) 265 (360) 30mm socket
51/52 05399 / 05406 Valve Assemblies n/a Valve puller (p/n 07662) - included w/ pump
58 05087 Hexagon Socket Screw 132 (180) 12mm allen wrench
K5 07381 Hexagon Socket Screw n/a 8mm allen wrench
GP8000 Trouble Shooting
Problem Cause Solution
Pressure drops, water leaks V-sleeves leak Replace V-sleeves, examine surface of
lunger
Dischar
Pressure drops, pump
becomes loud
Irregular pressure
Oil leaks at visible part of
lunge
Dirty mile-colored frothy oil Oil has mixed with water Replace oil immediately, find and fix the cause
Oil leaka
Noise increases without loss of
pressure
e on the crankshaft Shaft seal ring leaks Check seal and shaft
Steam formation (cavitation) Reduce suction height, reduce flow resistance
Worn valves Examine valves
O-Ring on the valves or inlet valve
ada
Gear sealing is leaky Examine seals and running surface of plunger
Worn bearing Dismantle gear, examine all parts, replace
e or suction valve leaks Replace valve
in inlet line, clean inlet filter, lower water
tem
Examine O-ring, examine valve casing for
ter leaks
unevenness on the sealing surfaces
worn parts, check oil level. If service life was
too short, check for excess strain or whether
lubrication intervals were too long. Only
s
ecified lubricants are to be used
7
erature
GP8045/GP8048 PUMP REPAIR INSTRUCTIONS
Valve Inspection and Repair
1) Remove bolts (58). 2) Remove discharge
casing (50B) up and away .
To Check Seals and Plunger Pipe
3) Take out pressure springs
(57A). Pull out assembled
valves (51 & 52) with fitting tool.
4) The spring tension cap (51A, 52A) is
screwed together with the valve seat (51B or
52B). Screw off spring tension cap. Takeout
springs (51E, 52E) and valve plate (51C, 52C).
Check sealing surfaces and O-rings (51D,
52D). Replace worn parts. Coat threads of
valve seat with silicon grease or molycote antiseize Cu-7439 when reassembling. Before
refitting the valves, clean the sealing surfaces
in the casing and check for any damage.
Tighten caps (58) at 133 Ft-lbs; check torque
tension after 8-10 operating hours.
5) Remove hexagon nuts (49A) and
valve casing together with seal case
(38) from crankcase (1). If necessary , carefully tap the valve casing
(50) past the centering stud (50A)
using a rubber hammer.
IMPORTANT! If necessary , support
the valve casing by resting it on
wooden blocks or by using a pulley.
6) Remove tension screw (36C) and take
seal sleeve (39) together with all mounted
parts out of the drive. Pull plunger pipe out
of the seal assembly and check for any
damage. Carefully , remove seal rings (40)
and sleeves (42) with a screw driver.
8
GP8045/GP8048 PUMP REPAIR INSTRUCTIONS
7) Be careful not to damage the seal
sleeve (39) and pressure ring (41). Check the inner
diameter of the pressure ring for wear and if necessary replace together with seals (40) and (42). Clean
all parts. New parts should be lightly coated with
silicon grease before installation. Insert the seal unit
(40, 41, 42 43) into the sleeve. Push the ceramic
plunger carefully through the seals from the crankcase side. If necessary, the seals can be held tightly
using a suitable pipe support held on the other side of
the seal sleeve.
8) Take out the seal case (38) from the valve (if
necessary secure 2 screwdrivers in the front O-ring
groove to extract seal casing from valve casing).
Coat seals with silicon grease before installing.
Mounting surfaces of the crankcase
and the valve casing must be clean and free of
damage. The components must lie exactly and
evenly on one another. The same exactness applies
for all centering positions in the crankcase, pressure and valve casing.
8) Coat the seal sleeve lightly with anti-corrosive
grease (e.g. molycote no. Cu-7439) in its fitted area
towards the crankcase. Insert the seal sleeves in to
their crankcase fittings.Coat the threads of the
tension screw (36C) lightly with thread glue and
insert it together with a new copper ring (36D)
through the ceramic pipe. Turn the pump per hand
until the plunger (25) rests against the plunger pipe.
Tighten the tension screw at 30 Ft-lbs.
Thread glue must never come between
the plunger pipe (36B) and centering sleeve (36E).
Overtensioning of the plunger pipe by excessive
tightening of the tension screw and/or dirt or damage
on the mounting surfaces can lead to plunger pipe
breakage. Insert the seal tension spring (45) and Oring (39A) in to the seal sleeve (39).
Replacing Valve Casing:
9) Put seal cases (38) in the centering holes of the
valve casing, then push valve casing carefully on to
centering studs (50A). Tighten hexagon screws (49A)
evenly and crosswise at 266 Ft.-lbs.
The torque tension on the screws (49A)
must be checked after 8-10 operating hours; the pump
must be at zero pressure. Thereafter , the tension is
to be checked every 200 operating hours.
9
GP8045/GP8048 PUMP REPAIR INSTRUCTIONS
To Dismantle Crankcase Gear
10) T ake out plungers and seal sleeves as described
above. Drain the oil by taking off the plug (12). After
removing the clip ring (33B), lever out the seal retainer
(33) with a screwdriver. Open hose adaptor (K1 1) and
remove gear cover (K3). Remove the cooling vane plate
(K1) by removing the screws (K4)
12) Push connecting rod halves together with the
crosshead as far as possible into the crosshead guide.
T ake out bearing cover (14/14A) and push out crankshaft taking particular care that the con rod doesn’t get
bent. Check surfaces on the connecting rods (24),
crankshaft (22) and crossheads (25). Check the
surfaces of the crosshead guides in the crankcase for
any unevenness.
1 1) Remove the connecting rod screws (24).
Connecting rods are marked 1 to 3
for identification. Do not twist connecting rod
halves or interchange them. When reassembling,
the connecting rod must be fitted in their exact
original position on the crankshaft journals.
13) Reassemble in reverse order. Thread the long
end of the crankshaft together with the inner
bearing rings into the crankcase; then mount
outer bearing ring (20) and spacer ring (22A).
Mount connecting rod halves in their exact
original position and tighten at 37 Ft-lbs.
Connecting rods must be able to
move slightly sideways on the stroke journals.
14) Mount bearing cover (14A) and tighten screws (17) to 64 Ft-lbs. Adjust axial play (clearance) on the
crankshaft to minimum 0.1 mm / max. 0.15 mm using shims (21A/21B). The shaft should turn easily with little
clearance. Connecting rod must sit exactly in the middle of each crank pin. Fit the bearing cover (14) and
tighten the screws (17) at 64 Ft-lbs. Seal (32A) must always be installed so that the seal lip on the inside
diameter faces the oil. Possible axial float of the seal adaptor (33) to be compensated with shims (33C).
Mount cooling plate (K1) and gear cover (K3) with their respective seals (K2). When assembling the cooling
circuit line, make sure that the oil cooler connection (K7) is always joined to the upper connection (K3) of the
gear cover.
10
Dimensions - GP8045 / GP8048 - mm
11
GIANT INDUSTRIES LIMITED WARRANTY
Giant Industries, Inc. pumps and accessories are warranted by the manufacturer to be free from defects in
workmanship and material as follows:
1. For portable pressure washers and self-service car wash applications, the discharge manifolds will never
fail, period. If they ever fail, we will replace them free of charge. Our other pump parts, used in portable
pressure washers and in car wash applications, are warranted for five years from the dateof shipment for
all pumps used in NON-SALINE, clean water applications.
2. One (1) year from the date of shipment for all other Giant industrial and consumer pumps.
3. Six (6) months from the date of shipment for all rebuilt pumps.
4. Ninety (90) days from the date of shipment for all Giant accessories.
This warranty is limited to repair or replacement of pumps and accessories of which the manufacturer’s evaluation
shows were defective at the time of shipment by the manufacturer. The following items are NOT covered or will void
the warranty:
1. Defects caused by negligence or fault of the buyer or third party.
2. Normal wear and tear to standard wear parts.
3. Use of repair parts other than those manufactured or authorized by Giant.
4. Improper use of the product as a component part.
5. Changes or modifications made by the customer or third party.
6. The operation of pumps and or accessories exceeding the specifications set forth in the Operations
Manuals provided by Giant Industries, Inc.
Liability under this warranty is on all non-wear parts and limited to the replacement or repair of those products returned
freight prepaid to Giant Industries which are deemed to be defective due to workmanship or failure of material. A
Returned Goods Authorization (R.G.A.) number and completed warranty evaluation form is required
return to Giant Industries of all products under warranty consideration. Call (419)-531-4600 or fax (419)-531-6836
to obtain an R.G.A. number.
prior to the
Repair or replacement of defective products as provided is the sole and exclusive remedy provided hereunder and
the MANUFACTURER SHALL NOT BE LIABLE FOR FURTHER LOSS, DAMAGES, OR EXPENSES, INCLUDING
INCIDENTAL AND CONSEQUENTIAL DAMAGES DIRECTLY OR INDIRECTLY ARISING FROM THE SALE OR
USE OF THIS PRODUCT.
THE LIMITED WARRANTY SET FORTH HEREIN IS IN LIEU OF ALL OTHER WARRANTIES OR REPRESENTATION, EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION ANY WARRANTIES OR MERCHANTABILITY
OR FITNESS FOR A PARTICULAR PURPOSE AND ALL SUCH WARRANTIES ARE HEREBY DISCLAIMED AND
EXCLUDED BY THE MANUFACTURER.
GIANT INDUSTRIES, INC.
900 N. Westwood Ave.
P.O. Box 3187
Toledo, Ohio 43607
(419) 531-4600
FAX (419) 531-6836
www.giantpumps.com
Copyright 2008 Giant Industries, Inc.
3/08 GP8045, GP8048.PMD
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